TRAIL BOSS 330 Model #A03CA32AA Model …pi54.com/corp/manuals/Parts/9917862r02.pdf19 1013519 1 Bracket, Lower, Oil Cooler 20 7080999 1 Cable Tie 4/03 A10 EXHAUST SYSTEM TRAILBOSS330A03CA32AAandTRAILBOSS330A03CA32AB

PARTS MANUAL PN 9917862 and MICROFICHE PN 9918976 3/03

TRAIL BOSS 330Model #A03CA32AAModel #A03CA32AB

Rev. 02

E 2002 Polaris Sales Inc.

TABLE OF CONTENTSTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

Parts Manual

AA--ARM/STRUT MOUNTING B7. . . . . . . . . . . . .AIR BOX A11. . . . . . . . . . . . . . . . . . . . . . . . . . .

BBUMPER and RACK MOUNTING A6. . . . . . . . .

CCARBURETOR C9-10. . . . . . . . . . . . . . . . . . . . . . .CLUTCH COVER B12. . . . . . . . . . . . . . . . . . . . .CONTROLS -- MASTER

CYLINDER/BRAKE LINE B5. . . . . . . . . . . .CRANKCASE C6. . . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT and PISTON C8. . . . . . . . . . . . .CYLINDER C7. . . . . . . . . . . . . . . . . . . . . . . . . .

DDECALS A5. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH B13. . . . . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH B14. . . . . . . . . . . . . . . . . . . . .

EELECTRICAL C1. . . . . . . . . . . . . . . . . . . . . . . .ENGINE MOUNTING A7-8. . . . . . . . . . . . . . . . . .EXHAUST SYSTEM A10. . . . . . . . . . . . . . . . . . .

FFRONT BRAKE B1. . . . . . . . . . . . . . . . . . . . . .FRONT CAB A3. . . . . . . . . . . . . . . . . . . . . . . .FRONT WHEEL A14. . . . . . . . . . . . . . . . . . . . . .FUEL PUMP D2. . . . . . . . . . . . . . . . . . . . . . . . .FUEL TANK A12. . . . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR C5. . . . . . . . . . . . . . . . . . . .

GGEARCASE C3-4. . . . . . . . . . . . . . . . . . . . . . . . .GEARCASE MOUNTING C2. . . . . . . . . . . . . . .

HHANDLEBAR B8. . . . . . . . . . . . . . . . . . . . . . . .

IINTAKE and EXHAUST C11. . . . . . . . . . . . . . . . .

MMAGNETO C14. . . . . . . . . . . . . . . . . . . . . . . . . .

OOIL COOLING A9. . . . . . . . . . . . . . . . . . . . . . .OIL PUMP and OIL FILTER C13. . . . . . . . . . . . . .

RREAR BRAKE MASTER CYLINDER B3. . . . . . .REAR CAB and SEAT A4. . . . . . . . . . . . . . . . .REAR CALIPER MOUNTING B2. . . . . . . . . . . .REAR HOUSING B9. . . . . . . . . . . . . . . . . . . . .REAR WHEEL DRIVE B10. . . . . . . . . . . . . . . . . .RECOIL STARTER C12. . . . . . . . . . . . . . . . . . . .

SSTARTING MOTOR D1. . . . . . . . . . . . . . . . . . .STEERING POST B6. . . . . . . . . . . . . . . . . . . . .STRUT A13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .SWING ARM/SHOCK MOUNTING B11. . . . . . . .

TTAILLIGHT C1. . . . . . . . . . . . . . . . . . . . . . . . . .THROTTLE CONTROLS / THROTTLE CABLE B4TOOL KIT D3. . . . . . . . . . . . . . . . . . . . . . . . . . .

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

A3

FRONT CABTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

4

5

6

2

7

14

16

3

3

109

8

1211

3

1


16

14

13

15

15

13

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 2632284-3412632284-42458121385811797

1111

Asm., Panel/Foam, LH (AA)Asm., Panel/Foam, LH (AB)Foam, Panel, LHFoam, Side Panel, LH

2 2632482-3412632482-4245812385

111

Asm., Panel/Foil, RH (AA)Asm., Panel/Foil, RH (AB)Foil, Foam, Side Panel, RH

3 7517916 4 Screw4 5432088-341

5432088-42411

Cover, Front (AA)Cover, Front (AB)

5 7670085 2 Clip, Spring6 2632303-341

2632303-42411

Cab, Front (Incl. Warning Decals)(AA)Cab, Front (Incl. Warning Decals)(AB)

7 7670057 2 Nut, U-Type Speed8 7512085 2 Screw9 7542122 2 Nut, Nylok10 7555859 2 Washer, Flat11 7541925 2 Nut, Nylok12 7555792 2 Washer13 7081040 8 Rivet14 7670088 4 Clip, Dart15 5245394-067

5245533-06711

Shield, Splash, LHShield, Splash, RH

16 5811917 2 Shield, Deflector

4/03

A4

REAR CAB and SEATTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

21

31

2

25

1

34

9

8

10

1112

26

67

14

15

20

22

30

32

27

29

5

1716

33

2813

25

18

19

1

4

23

24




1 7541925 4 Nut, Nylok2 5246091 1 Retainer, Seat Latch3 7512242 4 Screw4 7555859 10 Washer, Flat5 7512085 2 Screw6 5434040 1 Box, Tool7 7517375 2 Screw8 7621403 2 Rivet9 5211033 2 Bracket, Lever Retainer10 1040387 1 Latch, Seat11 7041370 1 Spring, Latch12 2682957-320

2682958-3202682957-0702682958-070

1111

Asm., Seat, Silver (Incl. 8-13)(AA)Covering, Seat(AA)Asm., Seat, Black (Incl. 8-13)(AB)Covering, Seat(AB)

13 5412067 8 Bumper, Rubber14 5431787 1 Cover, Tool Box15 5410896 1 Cap, Drain16 5241403-067 1 Guard, Clutch

17 7661637 4 Rivet18 5432763 1 Guard, Rock19 7515179 6 Screw20 5431771-070

5434417-07011

Footwell, Black, LHFootwell, Black, RH

21 7542122 8 Nut, Nylok22 7517376 8 Screw23 5245898 2 Mount, Cab, Rear24 7661637 2 Rivet25 7555792 4 Washer26 7170007 1 Decal, Carb/Filter Information27 5811087 1 Foil28 5811106 2 Foil, Rear Cab, Front29 5811111 1 Foil, Rear Fender30 5432117-341

5432117-42411

Cab, Rear, Sonic Blue Metallic (AA)Cab, Rear, Wine Invasion (AB)

31 7511930 2 Bolt32 7081040 14 Rivet33 5811107 1 Foil, Rear Cab, Rear

4/03

A5

DECALSTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

13

7

1

15

2

14

16

3

9

4

1012

6

11

5

8




1 7078465 1 Logo, Polaris Star2 7079773 1 Decal, Front Cover, “POLARIS”3 7170025 1 Decal, Ignition4 7079906 1 Decal, Override Switch, 2WD5 7170952 2 Decal, Rack Warning, Front & Rear6 7079959 1 Decal, “POLARIS”, Rear7 7079925 2 Decal, Reflector8 7079088 1 Decal, Tire Pressure/Load9 7077920 1 Decal, Passenger Warning10 7170656

717065771716477171648

1111

Decal, “2x4”, CDS, LH (AA)Decal, “2x4”, CDS, RH (AA)Decal, “2x4”, Side Panel, LH (AB)Decal, “2x4”, Side Panel, RH (AB)

11 71706547170655

11

Decal, “POLARIS”, Side Panel, LHDecal, “POLARIS”, Side Panel, RH

12 7170652717065371716437171644

1111

Decal, Tank Side, Trail Boss, LH (AA)Decal, Tank Side, Trail Boss, RH (AA)Decal, Tank Side, Trail Boss, LH (AB)Decal, Tank Side, Trail Boss, RH (AB)

13 7079085 1 Decal, Discretionary Warning14 7079083 1 Decal, Warning, General, CPSC15 7078577 1 Decal, Drain Recoil16 7078253 1 Decal, Warning, Age

4/03

A6

BUMPER and RACK MOUNTINGTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

2

4

1

2321

22

3

5

169

17

11

13

12

6

14

18

18

10

819

20

7

8

8

9

15

22




1 7517977 2 Bolt2 1014039-067

1014039-38511

Rack, Rear (AA)Rack, Rear (AB)

3 5432831 2 Plug, End Cap4 5334092 2 Spacer5 1014105-067

1014347-06711

Frame, Main (If built before 12/01/02)Frame, Main (If built after 12/01/02)

6 5810467 1 Plug, Frame7 7547069 2 Nutsert8 7512232 6 Screw9 7515399 4 Screw10 1013744-067

1013746-06711

Support Rack, Front, LHSupport Rack, Front, RH

11 7515189 2 Screw

12 2410285 2 Asm., Headlight13 7542122 2 Nut, Nylok14 1014040-067

1014040-38511

Bumper, Front (AA)Bumper, Front (AB)

15 7555827 2 Washer16 5245342-067 1 Shield, Radiator Side, LH17 5245343-067 1 Shield, Radiator Side, RH18 7661121 13 Rivet19 5245357-067 2 Bracket, Shield20 5334231-067 2 Support, Grill21 7542324 2 Nut, Nylok22 7558402 4 Washer, Flat23 7512329 2 Screw

4/03

A7

ENGINE MOUNTINGTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

1

2

6

7

15

11

10

98

1412

16

18

17

19

23

22

21

252627

30

28

29

31

32

34

3613

24

37

5

34

4

3

32

32

32

12

77

7

7

7

14

1011

20

33

333335


32

32

A8

ENGINE MOUNTINGTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB



1 8450003-1525 AR Line, Fuel2 7052075 1 Fitting, Tee3 7542122 2 Nut, Nylok4 7558301 2 Washer, Flat5 5243747-067 1 Bracket, Carburetor Mount6 3084205 2 Screw and Washer7 7547108 7 Nut, Flange Lock8 4010132 1 Cable, Ground, Engine9 7512232 1 Screw10 7512315 2 Bolt11 7552901 2 Washer, Spring Lock12 3021181 2 Mount, Rubber13 5430802 1 Insulator, Motor Mount14 7555823 2 Washer, Flat15 5243307-067

5247344

1

1

Bracket, Engine Mount, Top(If built before 2/17/03)Bracket, Engine Mount, Top(If built after 2/17/03)

16 7078577 1 Decal, Drain Recoil17 7080511 1 Clamp18 5411721 1 Boot, Clutch Intake19 8360009-100 AR Line, Fuel

20 1211750 1 Asm., Engine, Trail Boss 33021 7555815 1 Washer22 3110046 1 Mount, Rubber, Front23 1013413-067 1 Mount, Engine, Rear24 7547089 2 Nut, Flange Lock25 7515417 2 Screw26 5243288-067

5247342

1

1

Mount, Lower Front(If built before 2/17/03)Mount, Lower Front(If built after 2/17/03)

27 5430261 1 Bushing28 7575202 1 Washer, Lock29 7512566 1 Bolt30 5210748 1 Washer, Flat31 4010095 1 Cable, Battery/Engine32 7080003 8 Clamp, Hose33 8450103-600 AR Line, Fuel34 2530009 1 Filter35 8450040-600 AR Line, Fuel36 7546601 2 Nut, Nylok37 3110050 1 Mount, Carburetor

5/03

A9

OIL COOLINGTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

12

1

11

9

4

14

8

10

6

18

17

19

5

16

14

7

7

15

20

2

3

1514

13




1 54120395412355

22

Hose, Inlet (AA)Hose, Inlet (AB)

2 7080851 1 Clamp, Hose3 7512084 1 Screw4 7080862 2 Clamp, Hose5 7542122 4 Nut, Nylok6 5245416-067 1 Bracket, Oil Cooler, Top7 7515133 4 Bolt8 7517659 4 Screw9 2410157 1 Motor, Fan10 7670111 4 U-Clip

11 5433353 1 Shroud12 4010274 1 Thermister13 2410380 1 Jumper, Thermistor14 7558301 4 Washer15 7552801 4 Washer, Spring Lock16 7512240 4 Bolt17 1240074

124011811

Cooler, Oil (AA)Cooler, Oil (AB)

18 5411548 4 Mount, Rubber19 1013519 1 Bracket, Lower, Oil Cooler20 7080999 1 Cable Tie

4/03

A10

EXHAUST SYSTEMTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

109

1612

13

7

17

3

1

9

8

2

10

5

15

4

6

14

14

14

13 18

15

11

12




1 7542324 1 Nut, Nylok2 7555716 1 Washer, Flat3 5410436 1 Washer, Rubber4 5132295 1 Bushing5 5411790 1 Dampener, Vibration6 7515394 1 Bolt, Carriage7 1261182-029 1 Silencer8 7512666 1 Bolt9 3110064 2 Mount, Torque Stop

10 7542301 2 Nut11 5243642 1 Bracket, Mount, Silencer12 7512232 4 Screw13 7041769 2 Spring, Extension14 7041804 4 Spring, Exhaust15 5243517 2 Seal, Exhaust16 5243643 1 Bracket, Exhaust Pipe Support17 1260987-029 1 Headpipe18 1260960-029 1 Manifold

7/02

A11

AIR BOXTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

19

7

17

10

18

27

8

9

25

3

4

21

23

22

12

11

13

1

2

20

141516

26

6

5

24

23

24




1 7515180 1 Screw2 7558301 1 Washer, Flat3 5812023 1 Seal, Intake4 5433767 1 Duct, Inlet5 7517317 1 Screw6 5810317 1 Pad, Fuel Tank Bracket7 5433769 1 Cover, Air Box8 5811482 1 Seal, Air Box Cover9 5242044 6 Clip10 5432601 1 Collar, Carb Inlet11 7080699 1 Clamp, Hose12 5412101 1 Cap, Rubber13 5411866 1 Hose, Breather14 7080511 1 Clamp, Narrow Band

15 5411588 1 Boot, Carburetor16 7080413 2 Clamp, Narrow Band17 5433180 1 Duct, Carb Inlet18 5830128 1 Gasket, Carb Inlet19 5433919 1 Box, Air Intake, 4 Stroke20 7555932 2 Washer, Nylon21 5432377 1 Plug, Trap22 5812111 1 Foil, Air Box, RH23 7080650 1 Clamp, Hose24 5412099 2 Cap, Rubber25 7080413 1 Clamp, Narrow Band26 5811660 1 Precleaner27 1253372 1 Asm., Filter (Incl. 26)

10/02

A12

FUEL TANKTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

4

5 7

9

8

10

15

16

20

19

1718

15

13

1 3

2

6

21

15

22

14

14

1515

11

12

14

14

14

14




1 2520183 1 Tank, Fuel2 5433687 1 Cap, Gas Tank3 5812123 1 Gasket4 8360009-600 AR Hose, Vent5 5431053 1 Vent, Tank6 7512249 2 Screw7 7552801 2 Washer, Spring Lock8 7555859 2 Washer, Flat9 5222154

522215511

Bracket, Cover Mount, Rear, LHBracket, Cover Mount, Rear, RH

10 5811951 1 Seal, Foam11 5332457 2 Tube

12 7547069 4 Nutsert13 5810317 2 Pad, Fuel Tank Bracket14 7080003 8 Clamp, Hose15 8450040-600 AR Line, Fuel16 2530009 1 Filter, Fuel17 7052146 1 Fitting, Fuel Outlet18 7052149 1 Fitting, Fuel Outlet, Reserve, 90 Degree19 7052161 1 Valve, 3-Way20 5432733 1 Nut, Fuel Valve21 5432559 1 Knob, Fuel Valve22 7517505 1 Screw

7/02

A13

STRUTTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

1

23

4

5

6

7

8 9

10

11

12

13

14

16

1315

17




1 7547104 2 Nut, Nylok, Thin2 7555749 2 Washer3 5810291 2 Spacer, Rubber4 5432872 2 Pivot, Ball, Top5 5432871 2 Pivot, Ball, Bottom6 5132062 2 Spacer7 5243364 2 Retainer, Spring8 7041850-067 2 Spring, Compression9 5411608 2 Bumper

10 7041761 2 Strut, Front11 7080367 2 Clamp, Cable12 7542324 4 Nut, Nylok13 7558402 6 Washer, Flat14 7080306 2 Fitting, Lubrication15 7515339 4 Bolt16 5131039

513104011

Support, Strut/Spindle, LHSupport, Strut/Spindle, RH

17 5211115 2 Washer

7/01

A14

FRONT WHEELTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

1

23 4

5 6

7

8

93

1112

1415

16

17

18

10

13




1 ------ -- -- -- -- 1 Support, Strut and Spindle(See Strut Pg. A13, Ref. 16)

2 3610020 2 Seal, Hub, Front3 3513519 4 Bearing, Ball4 5243675

524683222

Disc, Brake (If built before 7/31/02)Disc, Brake (If built after 7/31/02)

5 5132627 2 Hub, Wheel6 5412324 2 Tire, Front (23x7-10)7 1520175-133

1520175-11722

Rim, Front (AA)Rim, Front (AB)

8 1525017 2 Valve, Rim

9 5010256 2 Spacer, Hub, Front10 7555721 2 Washer11 7542712 2 Nut, Castle12 7661407 2 Pin, Cotter13 7511866 2 Screw14 5433868 2 Cap, Hub15 5410470 2 O-Ring16 7547237 8 Nut, Flange17 7515513 8 Stud18 7512325 8 Bolt

4/03

B1

FRONT BRAKETRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

1

2 3

89

11

10

14

4

5 6 7

1213




1 7080352 1 Screw, Bleeder2 7515489 1 Screw, Socket Set3 1910695

1910696

1

1

Asm., Front Brake Caliper, LH(Incl. 1-7,9,10)Asm., Front Brake Caliper, RH(Incl. 1-7,9,10)

4 1930665 1 Kit - Piston and Seal (Incl. 5-7)5 5410779 1 Ring, Molded Square (.094)6 5410780 1 Ring, Molded Square (.103 x .134)

7 5132294 1 Piston, Brake, Long8 2202412 1 Kit - Front Brake Pad

(Complete Set of 2 Pads)9 1910412 1 Mount, Caliper10 5410495 1 Boot, Bushing11 5410494 1 Boot, Pin Seal12 7558402 4 Washer, Flat13 7552901 4 Washer, Spring Lock14 7512365 4 Screw

7/02

B2

REAR CALIPER MOUNTINGTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

11

15

16

18

17

14

1312

1

10

4

3 64

19

Frame

5

6

7

7

89

2

5

5




1 7517231 2 Screw2 7555806 2 Washer, Flat3 1910691

220151022013852201048

1111

Asm., CaliperKit -- Piston, CaliperKit -- Seal (Incl. O-Rings, Seals)Kit -- Bleed Screw (Incl. Bleed Screw& Dust Cap)

4 5410988 4 Seal5 7670102 6 Clip, Silencer6 1910504 1 Line, Brake7 1910506 1 Line, Brake, Foot, Rear8 7080539 1 Clamp, Nylon

9 7621462 1 Rivet10 1910499 2 Bolt, Banjo11 5131759 1 Bushing, Caliper Mount12 7558402 2 Washer, Flat13 7552901 2 Washer, Spring Lock14 7512312 2 Bolt15 5131786 1 Mount, Caliper, Lower16 5131787 1 Mount, Caliper, Upper17 7512325 3 Bolt18 5242291-067 1 Guard, Disc, Brake19 2202411 1 Kit - Brake Pad

7/02

B3

REAR BRAKE MASTER CYLINDERTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

6

17

19

13

1

11

8

10

9

7

5

4

2

21

18

16

3

12

20

6

910

1315 14




1 7512113 2 Bolt2 5246010-067 1 Bracket, Reservoir Mount3 7542122 2 Nut, Nylok4 7517386 1 Screw5 1930854 1 Reservoir6 7080003 2 Clamp, Hose, Red7 1910438 1 Hose, Reservoir8 7661401 1 Pin, Cotter9 7555919 2 Washer10 5431107 2 Bushing11 1910375-067 1 Mount, Brake (If built before 12/01/02)

12 1910499 1 Bolt, Banjo13 5410988 2 Seal14 ------ -- -- -- -- 1 Line, Foot Brake, Rear (See Rear Cal-

iper Mounting Pg. B2, Ref. 7)15 7552801 2 Washer, Spring16 7515179 2 Screw17 1910311 1 Asm., Foot Brake Master Cylinder18 7542324 2 Nut, Nylok (If built before 12/01/02)19 1910376-067 1 Brake, Rod20 7041750 1 Spring, Torsion21 7515321 2 Screw (If built before 12/01/02)

4/03

B4

THROTTLE CONTROL / THROTTLE CABLETRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

3

1

6

5

4

2




1 5434113 1 Cover, Throttle Control2 5410193 1 O-Ring3 5411439 1 O-Ring

4 7080967 1 Cable, Throttle5 2010204 1 Asm., Throttle Control (Incl. 6)6 2010191 1 Asm., Throttle Clamp

7/02

B5

CONTROLS - MASTER CYLINDER/BRAKE LINETRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

14

17

8

11

12

13

13

1516

2

9

10

18

1

7

6

5

4

11

3

3




2010196 1 Asm., Master Cylinder1 5410988 2 Seal2 4110164 1 Switch3 7517899 2 Screw4 2201834 1 Kit - Master Cylinder Cap

(Incl. Cap, Screws, Sight, Gasket)5 2201836 1 Kit - Master Cylinder Park Brake Lever

(Incl. Lever, Spring)6 2201833 1 Kit - Master Cylinder Clamp

(Incl. Clamp, Screws)7 2201835 1 Kit - Master Cylinder Lever

(Incl. Pin, Lever, Clip)

8 1910504 1 Line, Brake, Stainless Steel, Rear9 7621462 2 Rivet10 7080539 2 Clamp, Nylon11 8360052-34 2 Tubing, Convoluted12 1910502 1 Line, Brake, Left Front13 7080138 8 Cable Tie14 7512024 2 Screw15 1910503 1 Line, Brake, Right, Front Stainless Steel16 7052292 1 Fitting, Cross17 1910472 1 Line, Brake, Stainless Steel18 1910499 1 Bolt, Banjo

7/02

B6

STEERING POSTTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

S

1

1

2

34

56

7

3

6

7

8

9

10

11

12




1 7542324 4 Nut, Nylok2 7080424 1 Fitting, Lubrication3 5433866 2 Bushing, Steering, Upper4 1013927-067 1 Post, Steering5 5246732 1 Bracket, Steering Upper6 7512377 4 Bolt, Carriage

7 7556162 2 Bushing8 5222393 1 Flangette9 3514352 1 Bearing10 7547158 1 Nut11 7661633 1 Pin, Cotter12 7558402 2 Washer, Flat

7/02

B7

A-ARM/STRUT MOUNTINGTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

1

5 67

8

11

10

12

14

21

2016

19

1718

24

23

25

22

27 26

28

13

3

2726 22

2

13

94

9

4


15



1 7542403 2 Nut, FLEXLOC2 7558403 2 Washer3 7661203 4 Pin, Cotter4 5411920 2 Boot, Seal5 5411291 2 Boot, Seal, Rod End6 7061034 2 Rod End, RH7 7542711 2 Nut8 5020927 2 Tie Rod9 7517909 2 Screw10 7061054 2 Rod End, LH11 7547028 2 Nut, Jam, LH12 1820806 2 Asm., Tie Rod (Incl. 5-10)13 7556099 4 Washer, Flat14 7547177 2 Nut Lock15 7661407 2 Pin, Cotter

16 5240717 2 Bracket, Ball Joint17 7512284 4 Screw18 7542438 2 Nut, Castle19 5410548 2 Boot, Rubber20 7080927 2 Joint, Ball21 ------ -- -- -- -- 1 Support, Strut/Spindle

(See Strut Pg. A13, Ref. 16)22 5434551 4 Bushing, A-Arm, Long23 7080433 2 Fitting, Lubrication24 2202278

220227911

Kit, A-Frame, LH (Incl. 22-23,26,27)Kit, A-Frame, RH (Incl. 22-23,26,27)

25 5133806 2 Shaft, A-Arm26 7512492 4 Screw27 7555832 4 Washer28 7518033 2 Screw

4/03

B8

HANDLEBARTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

4

1

6

7

10

11

13

14

16

18

21

20

8

5

1920

17

912

23

15

22




1 7078465 1 Logo Star2 7512024 2 Screw3 5432420 2 Cover, Screw, Hinged4 5434643-070 1 Panel, Instrument5 7515189 4 Screw6 5246406-067 1 Bracket, Instrument Panel7 ------ -- -- -- -- 1 Asm., Master Cylinder

(See Control - Master Cylinder/BrakeLine Pg. B5 for Details)

8 7081007 1 Cable, Choke9 5433903 1 Spacer, Switch, LH10 4010422

4010592

1

1

Switch, Handlebar, Hi/Lo/Rev. Override(If built before 2/03/03)Switch, Handlebar, Hi/LO/Off(If built after 2/03/03)

11 5433834-070 2 Grip, Handlebar12 5432952 1 Plug, Hole13 7517625 1 Screw

14 5334127-067 1 Tube, Handlebar15 5631147 1 Block, Handlebar16 7542122 4 Nut, Nylok17 7080631 1 Clip, Cable Retaining18 ------ -- -- -- -- 1 Asm., Throttle Control (See Throttle Con-

trols/Throttle Cable Pg. B4, Ref. 5)19 5631146 1 Block, Handlebar, Pegged20 4010390

40102784010321

54337335433534

111

11

Switch, IgnitionBlank, Key, Series 2000, 6700, 6800Blank, Key, Series 2200, 2300, 2700,2800. NOTE: Your key can be dupli-cated only by obtaining a key blankfrom Polaris and having it cut by mat-ing it with your existing key.Nut, IgnitionCover, Key

21 7080922 1 Nut, Choke Slide22 4010459 1 Panel Indicator Light

4/03

B9

REAR HOUSINGTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

1

8

13

1825

22

21

9

6

1516

11

23

10

19

24

12

14

2

7

21

7

1112

1314

17

4

4

20

53

35




1 7710472 2 Ring, Retaining2 5510313 2 Retainer, Nut3 7547196 2 Nut4 5411555 2 Seal, Foam5 7542439 6 Nut, Nylok6 5243678 1 Disc, Brake7 7515513 6 Stud8 1520259 1 Asm., Brake Disc Hub (Incl. 7)9 7710405 1 Ring, Retaining10 5010462 1 Spacer, Axle11 5410889 2 O-Ring12 3610070 2 Seal13 3554518 2 Bearing, Cone, Tapered14 3554517 2 Bearing, Cup, Tapered

15 5132098 1 Housing, Axle, Rear16 7080306 1 Fitting, Lubrication17 3221154 1 Link, Connector18 5133181 1 Axle, Rear19 3221153-078

3221151-078

1

1

Chain, 520, O-Ring, 78P(If built before 8/05/02)Chain, 520, O-Ring, 78P(If built after 8/05/02)

20 7547108 3 Nut, Flange Lock21 5211618-067 1 Guard, Sprocket, 42T22 5630586 1 Spacer23 3222061 1 Sprocket, 40T24 1520258 1 Asm., Sprocket Hub (Incl. 7)25 7512404 3 Bolt

4/03

B10

REAR WHEELTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

12

3

4 56

7

89

10

11

12

1

2

4 895

6

7




1 7512673 8 Bolt2 5131777 2 Hub, Rear Wheel, Large Flange3 7542714 8 Nut4 7555796 2 Washer, Cone5 7543005 2 Nut, Castle6 7661404 2 Pin, Cotter7 5411164 2 Cover, Dust, Hub

8 7555745 2 Washer, Flat9 1525017 2 Valve, Rim10 7670081 8 Pushnut11 1520183-133

1520183-11722

Rim, Rear, White (AA)Rim, Rear, Silver (AB)

12 5412323 2 Tire (22x11-10)

4/03

B11

SWING ARM/SHOCK MOUNTINGTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

6

52

4

24

3

25

1

27

7

8

12

9

15

28

13

29

14

1011

21 20

1918

17

26

23

22

9

13

1

16

23




1 7542439 2 Nut, Nylok2 7041986-067 1 Spring, Compression3 5630551 1 Cam, Adjusting4 7041960 1 Shock, Rear5 5241147 1 Retainer, Spring6 7515415 1 Screw7 7661046 2 Rivet8 5432727 1 Guide, Pad, Chain9 7080510 2 Fitting10 7547082 1 Nut11 7556035 1 Washer, Flat12 5434546 2 Bushing, Swing Arm, RH13 5131697 2 Bolt, Swing Arm Pivot14 5133167 1 Bushing, Swing Arm Pivot, RH15 1580111 1 Asm., Swing Arm (Incl. 9,12,28)

16 7078572 1 Decal - “Chain Free Play”17 5432854 1 Guard, Chain18 7515304 1 Screw19 5332828 1 Bushing20 7558402 1 Washer, Flat21 7542321 1 Nut, Flange22 7547066 2 Nut, Nylok23 7555883 4 Washer24 7170915 1 Decal - Hitch25 2200472 1 Kit - Hitch (Incl. 22-26)26 7512576 2 Bolt27 7515438 1 Screw28 5434545 1 Bushing, Swing Arm, LH29 5133166 1 Bushing, Swing Arm Pivot, LH

7/02

B12

CLUTCH COVERTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

6

24 10

1112

13

14

17

202122

7

98

18

19

5

23

4

4

12

3

1

2

15

16




1 7547067 3 Nutsert2 5242208-067 1 Bracket, Clutch Cover3 7517386 2 Screw4 7517916 1 Screw5 2632474 1 Asm., Shield6 2202438 1 Kit, Clutch Cover, Inner7 5434401 1 Duct, Inlet8 7517860 3 Bolt and Washer9 7080909 1 Clamp, Narrow Band10 5521578 1 Seal, Clutch Cover11 5434255-070 1 Cover, Clutch, Outer12 7512094 9 Screw13 7078689 1 Decal, Warning, Clutch Cover

14 7074782 1 Decal, “Automatic Transmission”15 5434264 1 Plug, Drain, Clutch Cover16 5410542 1 O-Ring17 5411489 1 Boot, Duct18 7080707 2 Clamp19 5434213 1 Duct, Air Outlet20 ------ -- -- -- -- 3 Screw and Washer

(See Crankcase Pg. C6, Ref. 8)21 5242046 1 Bracket, Clutch Seal22 5410575 1 Seal, Cover Case23 5411795 1 Stopper, Inner Clutch Cover24 5410489 1 Seal, Cover Case, Transmission

4/03

B13

DRIVE CLUTCHTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

14

1 2

3 4

713

5 6 7

8

12

11

9 10E 2002 Polaris Sales Inc.



1 7512176 6 Bolt2 7552801 6 Washer, Spring Lock3 3576510 1 Bearing, Cover4 7041157 1 Spring, Clutch5 5430945 6 Washer, Multilube6 1321457 3 Roller and Bushing7 5431936 6 Button, Clutch8 5210752

524298152107535210754

ARARARAR

Spacer (.020)Spacer (.025)Spacer (.032)Spacer (.050)

9 5630709 3 Weight, Shift (10RH)10 7512266 3 Bolt, Shoulder11 7541906 3 Nut, FLEXLOC12 3576504 1 Bearing, Moveable, 1/2 Inch13 5020422 3 Pin, Roller14 1321976 1 Asm., Drive Clutch, Wide

(Incl. All Less 4,9)

7/02

B14

DRIVEN CLUTCHTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

23

45

6

7

10

12

13

15

1617

3

1

9

14

8

11




1 7556120 AR Bushing2 3211077 1 Belt, Drive3 1321848 1 Asm., Driven Clutch (Incl. 7-17)4 5220646 1 Washer, Domed5 7552901 1 Washer, Spring Lock6 7515384 1 Bolt7 7555898 AR Washer8 7556076 AR Washer9 7556804 AR Washer

10 3576504 1 Bearing, Moveable, 1/2 Inch11 3576511 1 Bearing, Moveable, 1 Inch12 7041782 1 Spring, Clutch, Black13 5131446 1 Ramp, Stationary14 5210752 1 Spacer15 7710448 1 Ring, Retaining16 7511854 3 Bolt17 5430766 3 Button, Ramp

7/01

C1

ELECTRICAL/TAILLIGHTTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

14

5

67

89

11

15

2220

31 30

29

28

26

2415

1619

14

3

23

33

32

21

17

10

12

13

10

2

27

25

1813E 2002 Polaris Sales Inc.



1 2461057 1 Harness, Main2 2201795 1 Kit, Circuit Breaker, Fan3 2410320 1 Taillight w/Brake Light4 4032046 1 Lens, Taillight5 4032029 2 Screw, Taillight6 4030043 1 Bulb, Taillight7 4032045 1 Gasket, Taillight8 ------ -- -- -- -- 1 Backing, Taillight/Brake Light9 7670054 2 Nut, Speed10 4020149 3 Clip, Rosebud11 7080138 12 Cable Tie12 7670109 3 Clip, Routing13 7512024 4 Screw14 4010137 1 Limiter, LR44-315 7541925 4 Nut, Nylok16 7571602 4 Washer17 8360012-04 1 Trim, Edge

18 4010697 1 Module Electronic, Control19 7512007 2 Bolt20 4010093 1 Cable, Solenoid/Starter21 ------ -- -- -- -- 1 Switch, Magnetic

(See Magneto Pg. C14, Ref. 8)22 4010094 1 Cable, Battery/Solenoid23 7512027 2 Screw24 4010774 1 Battery25 2202147 1 Kit, Fusible Link26 5810290 3 Pad, Battery27 7670102 1 Clip, Silencer28 5432077 AR Tube, Battery Vent29 5410424 1 Strap, Battery Holddown30 7010032 2 Hook, Battery Strap31 4010095 1 Cable, Battery/Engine32 2202213 1 Kit - Battery Bolt33 5431769 1 Cover, Battery

4/03

C2

GEARCASE MOUNTINGTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

9

4

15

6

3

21

1413

7

8

5

1 2

2

2

4

4

4

5

5

10

1112

52

3

+

2

17

16




1 7517632 2 Screw2 7547089 6 Nut, Flange3 5242456-067 2 Bracket, Transmission Mount4 7512492 4 Screw5 7555806 4 Washer, Flat6 5210764

52110655211517

ARARAR

Shim (.020)Shim (.010)Shim (.030)

7 1012886-067 1 Mount, Transmission8 5243296-067 1 Spacer

9 7517646 1 Screw10 7517631 1 Screw11 7542440 1 Nut12 ------ -- -- -- -- 1 Plug, Drain

(See Gearcase Pg. C4, Ref. 35)13 7710434 1 Ring, Retaining14 3221043 1 Sprocket, 11T15 7517640 1 Screw16 8450003-1525 AR Line, Fuel17 7670116 1 Clip, Routing

7/02

C3

GEARCASETRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

20

2126

31

35

18

17

32

14

23

33

22

1516

34

45

11

40

10

1

1213

8

3938

3028

24

67

41

27

25

29

3637

32

9

19

26

1

12

42


C4

GEARCASETRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB



1 3233018 2 Bearing2 3233177 1 Ring, Retaining3 3233673 1 Washer, Thrust4 3233674 1 Sprocket, 19T5 3233010 1 Washer, Thrust6 3233675 1 Dog, Engagement, High/Reverse7 3233676 1 Shaft, Input8 3233677 1 Gear, 21T9 3233678 1 Bushing10 3233105 1 Washer11 3233106 2 Ring, Retaining12 3233019 2 Bearing13 3233961 1 Nut14 3233547 1 Bellcrank15 3233045 1 Ring, Retaining16 3233040 1 Washer17 3233548 1 O-Ring18 3233679 1 Shaft, Shift19 3234002 1 Switch, 3 Position20 3233749 4 Screw21 3233680 1 Bullet, Shifting

22 3233681 1 Spring, Compression23 3233872 1 Washer, Nylon24 3233682 1 Plug, Detent, Extension25 3233478 1 Dipstick26 3233788 2 Seal, Triple Lip27 3233524 1 Tube, Vent28 3234049 1 Gearcase, RH29 3233529 2 Pipe, Knock30 3233684 1 Shaft, Shift31 3233685 1 Fork, Shift32 3234048 1 Gearcase, LH33 3233636 1 Decal - Switch34 3233252 9 Screw35 3233687 1 Plug, Drain36 3233527 1 Bushing, Pivot37 3233035 1 Washer38 3233111 1 Chain, Silent, 60P, 11W39 3233688 1 Sprocket, 51T40 3233689 1 Shaft, Output41 3233690 1 Gear, 64T42 1341306 1 Asm., Gearcase (Incl. 1-41)

11/02

C5

GEAR SELECTORTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

1

2

3

4

16

13

5

10

8

9

1112

15

8

5

14

14

6

67




1 5411006 1 Cover2 7512024 1 Screw3 5411007 1 Knob, Gear Selector4 5131976 2 Spacer, Shifter5 5433103 2 Mount, Gear Selector6 7518001 2 Screw7 7556250 1 Washer8 7546707 2 Nut, FLEXLOC

9 7061102 1 Rod End, RH10 7547083 1 Nut, RH11 1821205 1 Rod, Shift Linkage12 7547198 1 Nut, LH13 7061101 1 Rod End, LH14 7555859 2 Washer, Flat15 7512277 2 Bolt16 1013678-067 1 Handle, Gear Selector

7/02

C6

CRANKCASETRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

36

12

13

9

5

15

18

19

16

7

17

14

12

10

11

8

12

4




1 3083669 1 Bushing, Starter2 3086741 2 Pin, Dowel3 3087125 1 Asm., Crankcase

(Incl. 1-5,9,13,15,18,19)4 3087157 1 Plug, Blind5 3087116 2 Pin, Dowel6 3086395 1 Bearing, Ball7 3084838 2 Pin, Straight8 3084205 3 Screw and Washer9 3084839 1 Seal, Oil

10 3087128 1 Gauge, Oil11 3087065 1 O-Ring12 3087066 2 Union13 3087155 1 Plug14 3084849 1 Union, Oil Pump15 3087156 2 Bolt, Flange16 3086749 1 Plug17 3082956 1 Gasket18 3087117 8 Bolt, Flange19 3086399 1 Bolt, Flange

7/01

C7

CYLINDERTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

3

22

21

15

12

4

11 14

17

12

23

24

5

139

29

20

2526

27

28

16

19

18

12

12

1718

4

13

13

467

810




1 3087259 2 Cover, Valve2 3086414 2 O-Ring3 3087159 4 Bolt, Flange4 3087158 13 Bolt, Flange5 3086417 1 Plug, Cylinder Block6 3087033 1 Cover, Breather7 3085850 1 Pipe8 3087034 1 Gasket9 3086418 4 Bolt and Washer10 3086410 2 Pin, Straight11 3084858 1 Seal, Intake Valve12 3084994 2 Guide, Valve13 3084798 3 Fin Damper A14 3084859 1 Seal, Exhaust Valve15 3087237 1 Asm., Cylinder Head

(Incl. 3,4,12-14,15,17)

16 3086421 1 Gasket, Exhaust17 3085326 2 Stud18 3080530 2 Washer19 3086787 2 Nut20 3084838 2 Pin, Straight21 3086407 1 Gasket, Cylinder22 3087236 1 Cylinder23 3087238 1 Gasket, Head24 3086416 1 Gasket, Cam25 3087050 1 Adapter26 3083166 1 Asm., Adapter Band (Incl. 27)27 3081497 1 Screw28 3086786 2 Bolt29 3087160 2 Bolt, Flange

7/02

C8

CRANKSHAFT and PISTONTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

7

16

6

5

15

14

10

8

11

2

1

4

9

1312

5

146

4

3




1 308724430872453087246

111

Piston Ring Set (STD)Piston Ring Set (0.25 O/S)Piston Ring Set (0.50 O/S)

2 308724130872423087243

111

Piston Set (STD)(Incl. 3,4)Piston Set (0.25 O/S)(Incl. 3,4)Piston Set (0.50 O/S)(Incl. 3,4)

3 3086846 1 Pin, Piston4 3084167 2 Clip5 3087240 2 Bolt6 3087239 1 Asm., Connecting Rod (Incl. 5,15)7 3087119 1 Crankshaft, Complete (Incl. 16)8 3240168 2 Key, Woodruff

9 3086434308643530864363086437

1111

SpacerSpacerSpacerSpacer

10 3086492 1 Sprocket 111 3085528 1 Nut12 3086767 1 Washer13 3083905 1 Nut, Lock14 3086427

30867983086799

222

Bearing (STD)Bearing (0.05 U/S)Bearing (0.25 U/S)

15 3086426 2 Nut16 3085815 2 Bearing, Ball

7/02

C9

CARBURETORTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

42

32

29

9

45

5

44

12

4

6

3637

33

31

123013

12

1415

21

19

26

1110

3

22

20

16

24

18

25

35

23

46

3940

87

41

34

28

27

17

43

38


C10

CARBURETORTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB



1 3130507 1 Ring2 3130508 1 E-Ring3 3130730 1 Needle, Jet4 3130752 1 Ring5 3130732 1 Diaphragm6 3131457 1 Jet, Needle7 3130541 2 Screw8 3130540 2 Washer, Spring9 3131128 1 Asm., Jet Block10 3130014 1 Washer11 3131458 1 Jet, Main (#122.5)12 3130515 2 Seal13 3130517 1 Packing14 3130518 1 E-Ring15 3130519 1 Cap16 3130361 1 Pin, Float17 3130594 1 Plate18 3130532 1 O-Ring19 3130520 4 Screw20 3130590 1 Asm., Float Body21 3130521 1 Screw22 3130529 1 Asm., Float23 3130591 2 Screw

24 3131360 1 Valve, Needle (1.5)25 3130533 1 O-Ring26 3131421 1 Jet, Pilot (#42.5)27 3131423 1 Screw, Adjust28 3130836 1 Spring29 3131460 1 Valve, Throttle (100)30 3130589 1 Spring31 3130514 1 Ring32 3130501 2 Screw33 3130513 1 Asm., Throttle Shaft34 3130543 1 Guide, Cable35 3130535 4 Screw36 3130511 1 Cover37 3130512 1 O-Ring38 3130199 1 Cap, Plunger39 3130538 1 Spring40 3130593 1 Asm., Plunger41 3130625 1 Jet, Air (#160)42 3131456 1 Asm., Carburetor (Incl. 1-33,38-46)43 3084205 2 Screw and Washer44 3131129 1 Spring45 3131127 1 Asm., Cover46 3130592 4 Screw

4/03

C11

INTAKE and EXHAUSTTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

11

12

23

910

1314

8

76

4

2

16

24

2

15

27

1817

2526

28

1

31

5

2221

2019




1 3084911 2 Screw, Adjusting2 3084912 2 Nut3 3084910 2 Asm., Rocker Arm (Incl. 1,2)4 3087053 1 Shaft, Rocker5 3085836 1 Washer, Wave6 3084908 4 Collet, Valve7 3087203 2 Retainer, Spring8 3087248 2 Spring, Valve9 3086439 1 Lever, Release10 3086804 1 Spring, Return11 3087247 1 Camshaft (Incl. 9,10,12)12 3087254 1 Pin, Dowel13 3085778 1 Valve, Intake14 3086441 1 Valve, Exhaust

15 3086445 1 Guide, Chain16 3086444 1 Chain, Timing17 3086448 1 Gasket, Tensioner18 3086493 1 Tensioner19 3087132 1 Pin20 3087131 1 Spring21 3087130 1 Gasket22 3087129 1 Plug23 3083361 2 Bolt, Flange24 3086443 1 Sprocket 225 3087249 1 Washer26 3086449 1 Bolt, Flange27 3086446 1 Lever28 3084924 1 Bolt, Pivot

7/02

C12

RECOIL STARTERTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

13

6

4

7

10

5

31 2

11

8

12

14

9

8

7




1 3084822 1 Reel2 3083463 1 Spring, Return3 3083378 1 Ratchet4 3083379 1 Spring, Friction5 3084744 1 Plate, Friction6 3085266 1 Bolt and Washer7 3086749 2 Plug8 3082956 2 Gasket

9 3083669 1 Bushing, Starter10 3083185 1 Spring, Spiral11 3084750 1 Bushing12 3087150 9 Bolt, Flange13 3087163

308716411

Asm., Recoil (Incl. 1-6,9-11,13,14)Starter Case (Incl. 11)

14 3085083 1 Rope

7/02

C13

OIL PUMP and OIL FILTERTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

11

9

1

10

8

2

4

7

5

6

3E 2002 Polaris Sales Inc.



1 3086749 1 Plug2 3082956 1 Gasket3 3086455 1 Spring4 3086222 1 Valve, Relief5 3087256 1 Bolt, Flange6 3086454 1 Strainer, Oil

7 3084963 1 Filter, Oil8 3087255 5 Screw9 3086450 1 Cover, Oil Pump10 3086452 1 Rotor, Inner11 3086453 1 Rotor, Outer

7/02

C14

MAGNETOTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

7

4

6

12

10

8

3

5

9




1 30870363086484

11

Asm., Ignition Coil (Incl. 1,2)Coil, Ignition

2 3087037 1 Cap, Spark Plug3 3087257 1 Plug, Spark4 3084978 1 O-Ring5 3087252 1 Asm., Plate

6 3081657 5 Bolt and Washer7 3087251 1 Magneto8 3087196 1 Switch, Magnetic9 3087258 2 Bolt, Flange10 3087253 1 CDI System

7/02

D1

STARTING MOTORTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

9

11

1

5

10

4

3

17

12

16

15

14

13

67

8

21




3084981 1 Motor, Starting (Incl. 1-5,7-11)1 3084982 1 Washer Set2 3085353 1 Armature3 3084406 1 Brush, Carbon4 3083649 2 Nut, Flange5 3084408 3 O-Ring6 3082038 2 Bolt and Washer7 3085034 1 Bracket, Rear8 3085033 1 Asm., Front Bracket (Incl. 9)

9 3240114 1 O-Ring10 3084983 2 Asm., Set Bolt (Incl. 5)11 3084405 2 Ring, Rubber12 3083737 1 Washer, Gear Shaft13 3084412 1 Clip14 3084411 1 Spring, Weight15 3084410 1 Spring, Return16 3084409 1 Clip17 3087030 1 Asm., Gear Shaft (Incl. 12-16)

7/01

D2

FUEL PUMPTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

4

3

1 2

2

4




3085275 1 Asm., Fuel Pump (Incl. 3-4)1 3084591 4 Screw2 3085000 2 Screw and Washer

3 3084999 1 Screw and Washer4 3084998 1 Diaphragm Gasket Set

7/01

D3

TOOL KITTRAIL BOSS 330 A03CA32AA and TRAIL BOSS 330 A03CA32AB

1

3

4

5

6

7

2




1 2682572 1 Pouch, Tool Kit2 9917492

991824811

Owner’s Manual, ’03 ATVSupplement, Owner’s Manual, ’03Trail Boss 330

3 3083612 1 Wrench, Box, Special

4 3083613 1 Wrench, 10-12 Spanner5 3083843 1 Screwdriver6 2870725 1 Gauge, Tire Pressure7 3086485 1 Tool Kit (Incl. 1-6)

7/02

PRINTED IN THE USA PARTS MANUAL PN 9917862 and MICROFICHE PN 9918976 3/03

Changed

pages

in9917862

12

34

56

78

910

1112

1314

Acover

toc

x

B Cx

x

D E F G

12

34

56

78

910

1112

1314

Documents

TRAIL BOSS 330 Model #A03CA32AA Model …pi54.com/corp/manuals/Parts/9917862r02.pdf19 1013519 1 Bracket, Lower, Oil Cooler 20 7080999 1 Cable Tie 4/03 A10 EXHAUST SYSTEM TRAILBOSS330A03CA32AAandTRAILBOSS330A03CA32AB